Lower Completion Module

ABSTRACT

A technique that is usable with a well includes installing a lower completion module as a unit in the well. The lower completion module includes a flow control mechanism, an annular packer, a sand screen and a flow monitoring device. Either a single unit or a plurality of the units may be installed in the well for zonal isolation and control.

BACKGROUND

The invention generally relates to a downhole modular approach to alower completion to accomplish such functions as zonal isolation,inflow, outflow, optional monitoring and/or sand management.

A completed well typically includes a lower completion for purposes ofcommunicating and controlling the production of well fluid. The lowercompletion may include, as an example, packers to isolate variousproduction zones, screens to manage sand production and inflow controldevices.

The sand screens limit the production of particulates, or “sand.” Theproduction of sand from the well must be controlled in order to extendthe life of the well. One way to control sand production is to installscreens in the well and form a substrate around the screens to filtersand from the produced well fluid. A typical sand screen is formed froma cylindrical mesh that is generally concentric with the borehole of thewell where well fluid is produced. Gravel is packed in the annularregion that surrounds the sand screen. The produced well fluid passesthrough the gravel, enters the sand screen and is communicated upholevia tubing that is connected to the sand screen.

The inflow control devices regulate the rate at which well fluid flowsinto the lower completion. Without compensation, the flow distributionalong the sand screen is non-uniform, as the pressure drop across thesand screen inherently changes along its length. An uneven well fluidflow distribution may cause various production problems. Therefore, forpurposes of achieving a more uniform flow distribution, the inflowdevices may be disposed along the length to modify the fluid flowdistribution. The inflow control devices may also be used for purposesof shutting off production from a water producing zone, for example.

SUMMARY

In an embodiment of the invention, a technique includes installing alower completion module as a unit in a well. The lower completion moduleincludes a flow control mechanism, an annular packer, and a sand screen.

In another embodiment of the invention, an apparatus that is usable witha well includes a unit, which includes connectors to connect the unit toa string. The unit also includes an annular packer, a screen and a flowcontrol mechanism.

Advantages and other features of the invention will become apparent fromthe following drawing, description and claims.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic diagram of a lower completion module according toan embodiment of the invention.

FIG. 2 is a flow diagram depicting a technique to install components ina well according to an embodiment of the invention.

FIGS. 3, 4 and 5 are schematic diagrams of wells illustrating differentconfigurations that may be used with the lower completion moduleaccording to embodiments of the invention.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment 10 of a lower completion module inaccordance with the invention includes a screen 60, which receives anincoming well fluid flow 80 from a producing zone of a well. Inaccordance with some embodiments of the invention, the screen 60circumscribes an inner conduit, or base pipe 100, of the module 10. Thescreen 60, base pipe 100 and lower completion module 10 in general arecoaxial with a longitudinal axis 11. An annular region 90, which iscreated between the screen 60 and the outer surface of the base pipe100, receives the incoming well fluid. Unlike some conventional screens,the well fluid does not enter the base pipe 100 through openings thatare circumscribed by the screen 60. Instead, the lower completion module10 includes a flow control mechanism 50, which is longitudinally offsetfrom the screen 60 and controls fluid communication between the annularregion 90 and a central passageway 101 of the base pipe 100.

The flow control mechanism 50 may take on numerous forms depending onthe particular embodiment of the invention. As examples, the flowcontrol mechanism 50 may be a valve (and therefore, has a controlled,variable cross-sectional flow area) or may be an orifice that has afixed cross-sectional flow area. The flow control mechanism 50 may be achoke, such as a fixed choke or a variable choke. As another example,the flow control mechanism 50 may be a water or a gas shut-off valve.Regardless of the particular form of the flow control mechanism 50, themechanism 50 controls communication between the annular region 90 thatsurrounds the base pipe 100 and the central passageway of the base pipe100. Thus, when the flow control mechanism 50 allows communicationbetween the annular region 90 and the central passageway 101, theincoming well flow 80 enters the screen 60 and is communicated into theannular space 90 to form an annular flow 93 along the longitudinal axis11. The longitudinal flow 93 passes through the flow control mechanism50 and into the central passageway 101 of the base pipe 100 to form aflow 98 to the surface of the well.

In accordance with some embodiments of the invention, the flow controlmechanism 50 may be controlled by a wired or a wireless stimulus that iscommunicated from the surface of the well. In this regard, in accordancewith some embodiments of the invention, a control line (not depicted inFIG. 1) may communicate an electrical or a hydraulic signal to the flowcontrol mechanism 50 for purposes of opening and closing the flowcontrol mechanism 50, varying a cross-sectional flow path of themechanism 50, etc. Alternatively, a wireless stimulus, such as anelectromagnetic stimulus, seismic stimulus or pressure pulse (asexamples) may be remotely communicated from the surface of the well orother part of the well for purposes of controlling operation of the flowcontrol mechanism 50.

The lower completion module 10 may, in accordance with some embodimentsof the invention, include an interface 41 (a sensor-based interface, forexample) to detect command-encoded stimuli communicated to the module 10for purposes of controlling the flow control mechanism 50. In thismanner, in some embodiments of the invention, the interface 41 may, inresponse to the command-encoded stimuli, generate the appropriatesignals to control the flow control mechanism 50.

In some embodiments of the invention, the flow control mechanism 50 mayemploy autonomous control. In this regard, the lower completion module10 may include an interface 40, which senses one or more parameters ofthe zone in which the lower completion module 10 is located. As a morespecific example, the interface 40 may be attached to sensors, such astemperature and/or pressure sensors and other devices, such as snorkellines, for purposes of sensing a downhole condition. Thus, the lowercompletion module 10 may have at least one flow monitoring device tosense one or more parameters, such as a flow rate, a pressure, atemperature, a fluid composition, as few a few examples. In response tothe sensed condition(s), interface 40 may generate the appropriatesignals to control the flow control mechanism 50 in accordance with thesensor downhole condition(s).

The flow control mechanism 50 may be controlled by performing anintervention in the well, according to some embodiments of theinvention. More specifically, a service tool may be deployed into thewell for purposes of the intervention. As examples, the service tool maybe run into the well on a cable, tractor or pipe; may be dropped intothe well (such as when the tool is a dart, ball or rod); or may bepumped down into the well.

In addition to the screen 60 and the flow control mechanism 40, inaccordance with some embodiments of the invention, the lower completion10 includes an annular packer 110. As examples, the annular packer 110may be an external casing packer; a bladder (such as an inflatablebladder or a metal inflatable bladder, as examples); a packer formedfrom a swellable material; a packer formed from an ABT hydroformmaterial; a mechanical compression set packer; etc. Regardless of itsparticular form, the packer 110 may be controlled from the surface ofthe well; may be controlled by other downhole devices or tools; may becontrolled by an electrical signal; may be hydraulically controlled; maybe controlled by weight or mechanical movement of a string that isattached to the packer; and/or may be autonomously controlled forpurposes of controlling the radial expansion of the packer 110 to forman annular seal in the well. For example, for a packer that contains asealing element that is formed from a swellable material, the packer 110expands when sufficient exposure occurs to a particular well fluid ortriggering fluid. Alternatively, the radial expansion of the packer 110may occur in response to a sensed well condition, a wired or wirelessstimulus or pressure in the central passageway of the base pipe 100 (asjust a few examples). Thus, many variations are possible and are withinthe scope of the appended claims.

The lower completion module 10 includes connectors on its opposite endsfor purposes of releasably connecting the lower completion module 10 toother modules, tubular members, tubular strings, etc., depending on theparticular embodiment of the invention. As a more specific example, inaccordance with some embodiments of the invention, the lower completionmodule 10 includes an upper female connector 20, which includes anopening 22 for purposes of receiving a corresponding mating maleconnector. In general, the upper connector 20 may include internalbonded seals 23 for purposes for forming a sealed connection with theentity that mates with the lower completion module 10 through theconnector 20. As examples, the connector 20 may be a J-latch connector,bayonet connector or a threaded connector, depending on the particularembodiment of the invention.

In accordance with some embodiments of the invention, lower completionmodule 10 includes a lower connector 30, which may be a male-typeconnector that includes an extension 32 for purposes of forming acorresponding seal with a mating connector of a tubular string, otherlower completion module 10, etc. Depending on the particular embodimentof the invention, the lower connector 30 may be a J-latch connector,bayonet connector or a threaded connector, as just a few examples.

In accordance with some embodiments of the invention, the lowercompletion module 10 has an integrated housing. In this context, an“integrated housing” means a housing that may be formed from one or morehousing sections, which are connected together and are designed to beinstalled as a unit in the well. As an example, in accordance with someembodiments of the invention, the integrated housing may be formed froman upper housing 21 of the upper connector 20; a housing section 64 ofthe packer 110; the screen 60; and a lower housing 31 of the lowerconnector 30.

Referring to FIG. 2, to summarize, in accordance with some embodimentsof the invention, a technique 150 includes installing a lower completionmodule in a well. The installation may include installing a screen, flowcontrol mechanism and annular packer as a unit in the well, pursuant toblock 152.

The flexibility of the lower completion module permits a wide range ofcompletion configurations. For example, several screen modules 10 may beconnected serially together to form a completion assembly in accordancewith some embodiments of the invention. FIG. 3 depicts a well 200 inaccordance with some embodiments of the invention. The well 200 includesa tubular string 210, which has a section of serially connected lowercompletion modules 10. The string 10 extends inside a casing string 218of the well 200 such that the lower completion modules 10 are located invarious production zones of the well 200. It is noted that although FIG.3 depicts the well 200 as being cased, the well 200 may be uncased inaccordance with other embodiments of the invention. Additionally, thewell 200 may be a subterranean or a subsea well, depending on theparticular embodiment of the invention.

Each particular production zone of the well 200 may be formed by one ormore lower completion modules 10. The annular packer 110 of theuppermost lower completion module 10 of the zone is set; and likewise,the bottommost lower completion module 10 of the zone may also be set toform a corresponding sealed annular region in between. For each zone,well fluid flows from the surrounding formation through the screen(s) 60of the corresponding lower completion module(s) 10 and into the centralpassageway of the string 210.

It is noted that many different embodiments are possible and are withinthe scope of the appended claims. In this regard, the lower completionmodule 10 does not necessarily have to be connected to other lowercompletion modules 10 to fall within the scope of the appended claims.For example, referring to FIG. 4, in accordance with some embodiments ofthe invention, a well 240 may include a tubular string 242 that isconnected to a single lower completion module 10. The well 240 includesa tubular string 242, which may extend through a casing 241 of the well240, although the well 240 may be cased or uncased, depending on theparticular embodiment of the invention. The string 242 includes a lowercompletion module 10, which is connected in line with the tubular string242. Below the lower completion module 10 is a packer 250 that forms aconnection with the lower completion module 10. Thus, the annular packer110 of the lower completion module 10 and the packer 250 may be set toform a corresponding sealed annular zone for producing well fluid.

As another example, FIG. 5 depicts a well 300 in accordance with someembodiments of the invention. The well 300 includes a tubular string310, which extends inside a casing string 308, although the well 300 maybe cased or uncased, depending on the particular embodiment of theinvention. The string 310 includes a lower completion module 10 that isconnected to a conventional screen 320. Thus, the screen 60 of the lowercompletion module 10 may be in use in conjunction with one or moreconventional screens, which are not part of lower completion modules, asdescribed herein.

Although directional terms such as “up,” “down,” “uppermost,” etc. havebeen used for reasons of convenience for purposes of describing thelower completion module and its associated components andinterconnections. These orientations are not necessary to practice theclaimed invention. For example, the lower completion module 10 may belocated in a horizontal, or lateral wellbore in accordance with otherembodiments of the invention. Thus, many variations are contemplated andare within the scope of the appended claims.

While the present invention has been described with respect to a limitednumber of embodiments, those skilled in the art, having the benefit ofthis disclosure, will appreciate numerous modifications and variationstherefrom. It is intended that the appended claims cover all suchmodifications and variations as fall within the true spirit and scope ofthis present invention.

1. A method usable with a well, comprising: installing a lowercompletion module as a unit in the well, the lower completion modulecomprising a flow control mechanism, an annular packer and a sandscreen.
 2. The method of claim 1, wherein the lower completion modulefurther comprises a flow monitoring device.
 3. The method of claim 1,wherein the act of installing comprises: installing the sand screen, theflow control mechanism and the annular packer in an integrated housing.4. The method of claim 1, wherein the act of installing comprises:forming a connection between a connector of the unit and a tubularstring.
 5. The method of claim 4, wherein the connector comprises aJ-latch connector, a threaded connector or a bayonet connector.
 6. Themethod of claim 1, wherein the act of installing comprises: connectingthe unit to a tubular string.
 7. The method of claim 1, wherein the actof installing comprises: connecting the unit to another unit comprisinga flow control mechanism, an annular packer, a flow monitoring deviceand a sand screen.
 8. The method of claim 1, wherein the flow controlmechanism comprises a fixed choke, a variable choke or an on/off valve.9. The method of claim 1, further comprising: autonomously controllingthe flow control mechanism based on a response to a reservoir parameter.10. The method of claim 1, further comprising: performing anintervention in the well to control the flow control mechanism.
 11. Themethod of claim 10, wherein the act of performing the interventioncomprises an intervention selected from the following: running a servicetool on a cable, tractor or pipe; dropping the tool into the well; orpumping the tool down into the well.
 12. An apparatus usable with awell, comprising: a unit comprising connectors to connect the unit to astring, the unit comprising an annular packer, a screen and a flowcontrol mechanism.
 13. The apparatus of claim 12, wherein the unitcomprises an integrated housing connected to the screen, the flowcontrol mechanism and the annular packer.
 14. The apparatus of claim 12,wherein the tubular string comprises a connector to connect to one ofthe connectors of the unit.
 15. The apparatus of claim 14, wherein atleast one of the connectors of the unit comprises a J-latch connector, athreaded connector or a bayonet connector.
 16. The apparatus of claim12, wherein the connectors are adapted to connect the unit to a screen.17. The apparatus of claim 12, wherein the annular packer comprises aswell element, an external casing packer, an ABT hydroform, a mechanicalcompression set packer, an inflatable bladder or a metal inflatebladder.
 18. The apparatus of claim 12, wherein the screen comprises aslotted liner, a stand alone screen, a prepacked screen or a gravel packscreen.
 19. The apparatus of claim 12, wherein the flow controlmechanism comprises a fixed choke, a variable choke or a shut-off valve.20. The apparatus of claim 12, wherein the flow control mechanismcomprises: an interface comprising an interface adapted to be controlledvia a wireless stimulus, an interface adapted to be controlled inresponse to a dropped ball or an interface adapted to be controlled inresponse to a signal communicated over a control line.
 21. The apparatusof claim 12, wherein the flow control mechanism is adapted to beautonomously controlled.